Fuel saving combustion engine insulation method and system

Abstract

A method and apparatus for reducing fuel consumption in an internal combustion engine including gasoline, petrol and diesel engines used in trucks, cars and for pumps including the steps of providing a thermal insulation shield that includes reflective fabric over the exhaust manifold, around the intake plenum for intake air and intake air box, covering the turbo charger compressor with a heat insulating material that includes a reflective fabric layer and the turbo charger drive turbine housing except for the bearing area to greatly reduce heat build up in the engine compartment thereby reducing intake air temperature for increased engine efficiency. The invention has been found to increase fuel efficiency in large trucks by ten to fifteen percent. The materials are light weight and do not significantly increase engine weight or truck loan weight.

1. A method of reducing the increase of the temperature of intake air flowing through the intake air system to the combustion chamber(s) of an internal combustion engine mounted in an engine compartment comprising providing thermal shielding pre-configured for covering or wrapping an intake air conduit from an airbox to an intake air manifold of the engine, and applying the thermal shielding to the intake conduit to insulate the intake air from heat generated inside the engine compartment, further comprising applying thermal shielding to the turbine of a turbocharger for compressing intake air conveyed by the intake air conduit to the engine to reduce heat radiated and conducted from the turbine. 
     
     
       2. A method according to  claim 1 , further comprising applying thermal shielding to the airbox to insulate intake air airbox from heat generated inside the engine compartment. 
     
     
       3. A method according to  claim 1 , further comprising applying thermal shielding to the turbine and the compressor of the turbocharger to reduce heat radiated and conducted from the turbine and the compressor. 
     
     
       4. A method according to  claim 1 , further comprising thermally shielding an exhaust manifold for reducing heat radiated and conducted from the exhaust gas flowing through the exhaust manifold. 
     
     
       5. A method according to  claim 1 , wherein an intercooler is connected between an outlet of the compressor of the turbocharger and the intake air manifold of the engine and thermal shielding is applied to the intercooler. 
     
     
       6. A method according to  claim 5 , wherein the intake air conduit comprises a section extending from the airbox to an inlet of the compressor, a second section extending from an outlet of the compressor to an inlet of the intercooler and a third section extending from an outlet of the intercooler to the intake air manifold, thermal shielding being applied to each of the sections. 
     
     
       7. A method according to  claim 1 , further comprising lining with thermal shielding the underside of the hood for access to the engine compartment for channeling heat downwardly of the engine compartment. 
     
     
       8. A method according to  claim 1 , further comprising lining thermal shielding the underside of the hood for access to the engine compartment for channeling heat downwardly of the engine compartment. 
     
     
       9. A method according to  claim 1 , wherein the intake air conduit comprises a section extending from the airbox to an outlet of the compressor, a second section extending from an outlet of the compressor to an inlet of an intercooler and a third section extending from the outlet of the intercooler to the intake air manifold, thermal shielding being applied to each of the sections. 
     
     
       10. A method according to  claim 1 , wherein the intake air conduit comprises a section extending from the airbox to an inlet of the compressor, a second section extending from an outlet of the compressor to an inlet of an intercooler and a third section extending from the outlet of the intercooler to the intake air manifold, thermal shielding being applied to each of the sections. 
     
     
       11. A method of reducing the increase of the temperature of intake air flowing through the intake air system to the combustion chamber(s) of an internal combustion engine mounted in an engine compartment comprising:
 thermally shielding an intake air conduit from an airbox to an intake air manifold of the engine to insulate the intake air from heat generated inside the engine compartment; and 
 thermally shielding the turbine and the compressor of the turbocharger to reduce heat radiated and conducted from the turbine and the compressor; 
 wherein the turbine and compressor are selectively wrapped to leave exposed bearing portions. 
 
     
     
       12. A method according to  claim 11 , wherein the face of the compressor remote from the turbine is also left exposed. 
     
     
       13. A method of reducing the increase of the temperature of intake air flowing through the intake air system to the combustion chamber(s) of an internal combustion engine mounted in an engine compartment comprising:
 thermally shielding an intake air conduit or passage from an airbox to an intake air manifold of the engine to insulate the intake air from heat generated inside the engine compartment; and 
 thermally shielding the turbine of a turbocharger for compressing intake air conveyed by the intake air conduit to the engine to reduce heat radiated and conducted from the turbine; 
 wherein an intercooler is connected between an outlet of the compressor of the turbocharger and the intake air manifold of the engine and the intercooler is thermally shielded; 
 wherein the intake air conduit or passage comprises a section extending from the airbox to an inlet of the compressor, a second section extending the outlet of the compressor to an inlet of the intercooler and a third section extending from an outlet of the intercooler to the intake air manifold, each of the sections being thermally shielded; and 
 wherein a reflective and insulating wrap is used for thermally shielding, the reflective and insulating wrap comprising at least two layers including a metal coated or laminated insulating fabric and a nonwoven insulating web. 
 
     
     
       14. A method according to  claim 13 , wherein the non-woven insulating web is adhesive coated. 
     
     
       15. A method according to  claim 13 , wherein the reflective and insulating wrap for thermally shielding the turbine and compressor comprises at least three layers including an outer layer of metal coated or laminated insulating fabric, an intermediate layer of non-woven insulating web and an inner layer of metal wire mesh for contact with the housing of the turbine or compressor, and the reflective and insulating wrap for thermally shielding the airbox and the intake air conduit or passage comprises at least two layers including a metal coated or laminated insulating fabric and a non-woven insulating web. 
     
     
       16. A method according to  claim 15 , further comprising thermally shielding the exhaust manifold with the reflective and insulating wrap comprising at least three layers. 
     
     
       17. A method according to  claim 15 , wherein the reflective and insulating wrap for thermally shielding the turbine and compressor comprises four layers including a first or outer layer of metal coated or laminated insulating fabric, a second layer of non-woven insulating web, a third layer of a high temperature fiberglass lagging cloth, and a fourth or inner layer of metal wire mesh for contact with the housing of the turbine or compressor. 
     
     
       18. A method according to  claim 17 , wherein the non-woven insulating web is adhesive coated. 
     
     
       19. A method of reducing the increase of the temperature of intake air flowing through the intake air system to the combustion chamber(s) of an internal combustion engine mounted in an engine compartment comprising:
 thermally shielding an intake air conduit from an airbox to an intake air manifold of the engine to insulate the intake air from heat generated inside the engine compartment; and 
 thermally shielding the turbine and the compressor of the turbocharger to reduce heat radiated and conducted from the turbine and the compressor; 
 wherein a reflective and insulating wrap is used for thermally shielding the turbine and compressor, the reflective and insulating wrap comprising at least three layers including an outer layer of metal coated or laminated insulating fabric, an intermediate layer of non-woven insulating web and an inner layer of metal wire mesh for contact with the housing of the turbine or compressor. 
 
     
     
       20. A method of reducing the increase of the temperature of intake air flowing through the intake air system to the combustion chamber(s) of an internal combustion engine mounted in an engine compartment comprising:
 thermally shielding an intake air conduit from an airbox to an intake air manifold of the engine to insulate the intake air from heat generated inside the engine compartment; and 
 thermally shielding the turbine and the compressor of the turbocharger to reduce heat radiated and conducted from the turbine and the compressor; 
 wherein a reflective and insulating wrap used for thermally shielding the turbine and compressor comprises four layers including a first or outer layer of metal coated or laminated insulating fabric, a second layer of non-woven insulating web, a third layer of fiberglass lagging cloth, and a fourth or inner layer of metal wire mesh for contact with the housing of the turbine or compressor. 
 
     
     
       21. A system for reducing the increase of the temperature of intake air flowing through the intake air system to the combustion chamber(s) of an internal combustion engine mounted in an engine compartment comprising thermal shielding pre-configured for wrapping or covering an intake air conduit from the airbox to an intake air manifold of the engine for insulating the intake air from heat generated inside the engine compartment, further comprising thermal shielding configured to wrap or cover the airbox. 
     
     
       22. A system according to  claim 21 , further comprising thermal shielding configured to wrap or cover a turbine of a turbocharger. 
     
     
       23. A system according to  claim 22 , further comprising thermal shielding configured to wrap or cover a compressor of the turbocharger. 
     
     
       24. A system according to  claim 23 , further comprising thermal shielding configured to wrap or cover an exhaust manifold. 
     
     
       25. A system according to  claim 24 , further comprising thermal shielding configured to wrap or cover an intercooler. 
     
     
       26. A system according to  claim 24 , further comprising thermal shielding configured to wrap or cover a section of the intake air conduit or passage between an intercooler and the intake air manifold. 
     
     
       27. A system according to  claim 24 , further comprising thermal shielding configured to wrap or cover a section of the air inlet conduit or passage between an intercooler and the inlet air manifold. 
     
     
       28. A system according to  claim 23 , further comprising thermal shielding configured to line the underside of an access hood for an engine compartment. 
     
     
       29. A system according to  claim 22 , further comprising thermal shielding configured to wrap or cover a section of the intake air conduit or passage between the airbox and the compressor. 
     
     
       30. A system according to  claim 21 , further comprising thermal shielding configured to wrap or cover a section of the air inlet conduit between the airbox and the turbocharger. 
     
     
       31. A system for reducing the increase of the temperature of intake air flowing through the intake air system to the combustion chamber(s) of an internal combustion engine mounted in an engine compartment comprising a thermal shield configured for wrapping or covering an intake air conduit from an airbox to an intake air manifold of the engine for insulating the intake air from heat generated inside the engine compartment;
 wherein the thermal shield comprises at least two layers including a metal coated or laminated insulating fabric and a non-woven insulating web. 
 
     
     
       32. A system according to  claim 31 , further comprising a thermal shield for wrapping or covering the intake air conduit, the airbox comprising at least two layers including a metal coated or laminated insulating fabric and a non-woven insulating web. 
     
     
       33. A system according to  claim 32 , wherein the non-woven insulating web is adhesive coated. 
     
     
       34. A system for reducing the increase of the temperature of intake air flowing through the intake air system to the combustion chamber(s) of an internal combustion engine mounted in an engine compartment comprising:
 thermal shielding configured for wrapping or covering the intake air conduit or passage from an airbox to an intake air manifold of the engine for insulating the intake air from heat generated inside the engine compartment; 
 thermal shielding configured to wrap or cover a compressor of the turbocharger; and 
 thermal shielding configured to wrap or cover a turbine of a turbocharger; 
 wherein the thermal shielding for the compressor or the turbine comprises at least three layers including an outer layer of metal coated or laminated insulating fabric, an intermediate layer of non-woven insulating web and an inner layer of metal wire mesh for contact with the housing of the turbine or compressor. 
 
     
     
       35. A system for reducing the increase of the temperature of intake air flowing through the intake air system to the combustion chamber(s) of an internal combustion engine mounted in an engine compartment comprising:
 thermal shielding configured for wrapping or covering the intake air conduit from an airbox to an intake air manifold of the engine for insulating the intake air from heat generated inside the engine compartment; 
 thermal shielding configured to wrap or cover a compressor of the turbocharger; 
 thermal shielding configured to wrap or cover a turbine of a turbocharger; and 
 thermal shielding configured to wrap or cover an exhaust manifold; 
 wherein the thermal shielding for the compressor, the turbine or the exhaust manifold comprises at least three layers including an outer layer of metal coated or laminated insulating fabric, an intermediate layer of non-woven insulating web and an inner layer of metal wire mesh for contact with the housing of the turbine or the compressor, or the exhaust manifold. 
 
     
     
       36. A method of reducing the increase of the temperature of intake air flowing through the intake air system to the combustion chamber(s) of an internal combustion engine equipped with a turbocharger and an intercooler and mounted in an engine compartment, the intake air system comprising an intake air conduit including a section extending from the airbox to the inlet of a turbocompressor, a second section extending from the outlet of the turbocompressor to the inlet of the intercooler and a third section extending from the intercooler to the intake air manifold, the method comprising:
 providing reflective and insulating wrap comprising at least two layers including a metal coated or laminated insulating fabric and an insulating layer, the reflective and insulating wrap being preconfigured for each of the sections of the intake air conduit and the turbocharger; 
 thermally shielding each of the sections of the intake air conduit to insulate the intake air from heat generated inside the engine compartment; and 
 thermally shielding the turbocharger with reflective and insulating wrap to reduce heat radiated and conducted therefrom.